Materials

Throughout the battery from a single cell to a complete pack there are many different materials. Hence it is important to look at those in terms of their characteristics and application in battery design.

This page will be arranged A to Z so that you can quickly scan down and find the appropriate section.

Aluminium

Used in electrical busbars, cell cases, module housings and for pack cases. Hence a number of different grades of aluminium based on the requirements from electrical resistance, thermal conductivity, strength and corrosion resistance.

Copper

HV and LV Busbars, electrical tracks, connectors and for some anode current collectors, here ~10┬Ám thick.

Dielectric Coolant – an array of oils and synthetic liquids that are dielectric and hence prevent or quench electric discharge. There are single-phase and two-phase dielectrics that give a number of options for submersing the cells directly into the coolant.

Ethylene Glycol – organic compound used as a coolant, normally mixed 50:50 with water and then flows through isolated coolant plates that the cells interface with.

Nickel Plating – process that can enhance the corrosion resistance, durability, hardness, conductivity, and heat-resistance of a component.

Niobium – lots of interest as a substituted element into Nickel rich NMC chemistry to improve stability and hence reduce degradation.

Plastic

A vast array of plastics are used across the battery pack for structure, sealing, isolation and protection.

TIM – Thermal Interface Material

Normally a silicon based compound loaded with graphite to improve it’s thermal conductivity. The purpose of thermal interface materials (TIM) is to transfer heat between two solid surfaces. In the case of a battery this is normally between the outer surface of the cell case and a cooling plate.

V0 Plastics – sometimes used as an abbreviation to describe a plastic that meets the UL94:V-0 certification. The tested material has to self extinguish within 10 seconds on a vertical part allowing for drops of plastic that are not inflamed.